Chatter-resistant end mill and method of making

ABSTRACT

A method of making chatter-resistant end mills includes: (a) forming an end mill having unequal angular spacing between adjacent teeth, (b) cutting a test work piece with the end mill and measuring vibrations and resonance; (c) upon detecting undesired levels of vibration and resonance, adjusting the angular spacing between adjacent teeth to reduce vibration and resonance and forming another end mill having the adjusted angular spacing; (d) cutting a test work piece with the adjusted end mill and measuring vibrations and resonance; (e) repeating steps (c) and (d) until an end mill is formed in which vibration produced by the angular spacing between at least one pair of adjacent teeth cancels out at least a portion of the vibration produced by the angular spacing between at least one other pair of adjacent teeth; and (f) making at least one production end mill conforming to step (e).

BACKGROUND

The present application relates to milling cutters. More particularly,there is provided an end mill configured to substantially reduce oreliminate vibrations of the cutter itself and of the work piece.

The milling process is by its very nature a non-continuous form ofmachining. A wide range of cutters are available “off the shelf,” and itis up to the user to select the type required. The cutter used may haveup to about 20-30 teeth, depending primarily upon the diameter of thecutter and its type, and on further factors, such as the material ofwhich the cutter is constructed, the material of the work piece, whetherthe cutting operation is for finishing or roughing, the required ordesired cutter life, and the like.

As can be expected from any non-continuous type of machining, vibrationsare generated by milling, and such vibrations may range in amplitudefrom negligible to severe. During machining with an end mill, the toolis generally subject to both bending and torsional forces, these beingof an intermittent nature due to a tooth contacting or ceasing tocontact the face being machined. As those visiting a working machineshop are aware, these vibrations generate sounds which are infrequencies and amplitudes to which the human ear is sensitive.

The work piece being machined is also set into vibration, the nature ofwhich will be significant for a large hollow item and will be of noconsequence for a solid well-supported and securely clamped work piece.

Noticeable vibration, sometimes referred to as chattering, isdetrimental to machining not only because of the generated noise. Suchvibrations are directly responsible for a poor surface finish on thework piece, as well as for a shortening of the life of the cutter andreduced accuracy in machining.

Undesired vibrations may be present in the cutting tool, or in the workpiece, and can be present in both.

A severe problem arises when the frequency of vibration of the cuttercorresponds or is proximate to the natural frequency of the work piece,causing resonance. The resulting greatly increased amplitude makes itimpossible to produce acceptable work and the generated sound can bemost disturbing. Breakage of a cutter such as an end mill or spoilage ofthe work piece is also likely. The use of a more rigid cutter and theapplication of additional work piece supports would increase vibrationfrequency to a safe and non-audible level and greatly reduce amplitude,but these desirable steps are not always possible.

Increasing the cutter speed is also often impractical because tool lifewill be substantially shortened in practice.

The use of helical-tooth end mills, similarly to helical gearing, ishelpful in abating but not solving these problems.

The state of the prior art can be assessed from a review of relevantU.S. Patents.

In U.S. Pat. No. 4,285,618, Stanley, Jr. claims a milling cutter shownas an end mill provided with serrations on the cutting edges. Theserrations are axially off-set in relation to a neighboring tooth.Whether or not such a cutter will reduce vibrations would need to beproved by tests.

In U.S. Pat. No. 4,963,059, Hiyama proposes an end mill wherein theflute helix angle is not the same for each flute. However, as theperipheral cutting edges are equally spaced around the cutter peripheryin at least one position, the proposed design would provide only apartial solution. Also, a problem would arise during manufacture of saidend mill as the metal available for formation of the tooth would varysignificantly along the length of the cutter.

In U.S. Pat. No. 6,168,355, Wardell describes an end mill having a mainbody and ears extending outward from the point of the tool. Means forreducing vibration are not provided.

In U.S. Pat. No 6,164,877, Kamata et al. disclose a formed shape cutterintended for cutting specially-shaped grooves. The relief angle of thetooth remains constant along the axial length of the tool. Noanti-chatter means are seen.

Wardell, in a further U.S. Patent, discloses an end mill having aprimary helical flute defining a low-angle cutting surface and asecondary flute for a high angle cutting surface. This arrangement willnot solve the problems relating to tool vibrations.

A further end mill having a variable helix flute is seen in publishedU.S. Patent Application 2005/0105973 by MacArthur. The teeth of thecutter are equally spaced around the tool periphery.

From the prior art it is evident that no satisfactory solution is yetknown.

OBJECT

It is therefore one of the objects of at least one embodiment to obviatethe disadvantages of prior art cutters and to provide an end mill whichwill eliminate or substantially reduce periodic vibrations which aredetrimental to both the tool and the work piece.

It is a further object of at least one embodiment to disclose a tooldesign which can be easily programmed for manufacture, and can bemanufactured at a cost only slightly higher than a conventional endmill.

SUMMARY

The above objects may be achieved in at least one embodiment of achatter-resistant end mill, shell mills and burs comprising a shankportion and at least one cutting portion divided into a plurality ofteeth by flutes disposed between said teeth, each tooth having at leastone cutting edge, and wherein a first angle separating said cutting edgeof a first tooth from the cutting edge of a tooth nearest the firsttooth in a clockwise direction is different from a second angleseparating said cutting edge of said first tooth from the cutting edgeof a tooth nearest the first tooth in an anti-clockwise orcounterclockwise direction. For example, in an embodiment having onlytwo teeth, the first angle separating the cutting edge of the firsttooth from the cutting edge of the second tooth (which is nearest thefirst tooth since the second tooth is the only other tooth) in aclockwise direction is different from a second angle separating thecutting edge of the first tooth from the cutting edge of the secondtooth in a counterclockwise direction. In an embodiment having three ormore teeth, the first angle separating the cutting edge of a first toothfrom the cutting edge of a second tooth nearest the first tooth in aclockwise direction is different from a second angle separating thecutting edge of the first tooth from the cutting edge of a third toothnearest the first tooth in a counterclockwise direction.

In one embodiment there is provided an end mill wherein the differencebetween said first and said second angles is in the range of 0.2-60degrees.

In another embodiment there is provided an end mill wherein thedifference between said first and said second angles is in the range of0.2-30 degrees.

In another embodiment there is provided an end mill wherein the widthand depth of all flutes in said cutting portion is equal.

In a further embodiment there is provided an end mill or burs wherein aflute is disposed between two adjacent teeth, said adjacent teeth beingspaced apart at an angle exceeding the angle which would result fromequal angular spacing, said flute being wider and deeper than a secondflute appropriate to an equally-spaced pair of adjacent teeth.

In yet another embodiment there is provided an end mill or burs whereina flute is disposed between two adjacent teeth, said adjacent teethbeing spaced apart at an angle less the angle which would result fromequal angular spacing, said flute being narrower and shallower than asecond flute appropriate to an equally-spaced pair of adjacent teeth.

In a further embodiment there is provided an end mill, shell mills andburs wherein the flute helix angle is constant along each tooth andconstant from tooth to tooth in the cutting part of the end mills, shellmills and burs.

In a further embodiment there is provided an end mill, shell mills andburs wherein the flute helix angle is variable along each tooth and samefrom tooth to tooth in the cutting part of end mills, shell mills andburs.

In yet a further embodiment there is provided an end mill wherein atleast one group of said cutting edges is displaced from theequally-spaced position and at least one further group has cutting edgespositioned in an equally-spaced configuration.

It will thus be realized that the cutter of at least one embodimentserves to break the regularity of the input force causing the undesiredvibration both in the end mill and in the work piece. Resonance occurswhen the natural frequency of the cutter or of the work piececorresponds or is proximate to the frequency of the induced vibration.The end mill of at least one embodiment having irregularly spacedcutting surfaces will apply the cutting force in an irregularly timedcycle, the result of which is the inhibition of resonance, and greatlyreduced vibration at any frequency. Vibration control provides thedesired benefits of a better surface finish, longer tool life and, ofcourse, less noise.

Theoretical calculations of vibration frequencies for cutters and workpieces are difficult, because of the complex form of the tool and oftenalso of the work piece and because the end mill is stressed bothtorsionally and by bending forces. Measurement of vibration whilemachining a test piece is however a simple task. Furthermore, vibrationinput is easily calculated on the basis of number of teeth and the speed(RPM) of the machine spindle. Thus a simple test will indicate whichtool diameter and the benefits of uneven peripheral spacing of the teethin at least one embodiment are not limited to conditions of resonance.Whatever the natural frequency, unwanted vibration is subdued by theuneven peripheral positioning of the cutting edges. The reduction ofvibrations to minimum amplitude is a prerequisite for correct andeconomic machining by any machine tool.

A prototype of a cutter made according to at least one embodiment wastested with the following results:

Tools:

Solid Carbide End Mill Diameter 12 mm:

#1-5 flutes with unequal cutting edges space dividing according to anembodiment.

#2-5 flutes with equal cutting edges space dividing.

Material: St. Steel 316 L,

Cutting Conditions:

Slotting Application: depth of cut-12 mm (1D)

Feed Speed m/min mm/t # of tools 50 60 70 80 90 0.05 #1 - Vibrations NoNo No No No 0.05 #2 - Vibrations Slow Medium High High, High, ChippingBroken Speed Feed, mm/t m/min # of tools 0.03 0.04 0.05 0.06 0.07 80#1 - Vibrations No No No No No 80 #2 - Vibrations Slow High High, High,High, Chip- Broken Broken ping

Thus it was seen that the end mill according to at least one embodimentachieved the stated objects:

5 flutes Solid Carbide End Mills diameter 12 mm with unequal cuttingedges space dividing according to one embodiment prevent vibration inwide range of the speeds: 50-90 m/min and feeds: 0.03-0.07 mm/teeth.

According to at least one possible embodiment, the spacing between twoteeth of a cutter or end mill is adjusted by experiment to substantiallyor at least partially cancel out the vibration which is caused by thespacing between other teeth. To further explain by way of example, in anend mill with five cutting teeth, each pair of adjacent teeth defines anangular measurement there between. As discussed above, the angularmeasurements are not equal for all five pairs of cutting teeth in orderto substantially reduce or eliminate resonance caused by vibrations. Inorder to achieve such a substantial reduction or elimination ofvibrations, the spacing of the cutting teeth, and thus the angularmeasurement there between, can be selected during design of the end millfor each pair of teeth. If, for example, an angular spacing of at leastone pair of teeth is believed to have or actually has a canceling effecton vibrations caused by a different angular spacing of another pair ofteeth for an end mill for a particular type of machining, then the endmill could be designed accordingly. The end mill could then be tested ona test work piece, wherein the vibrations and/or resonance could bemeasured and observed to determine the degree of the canceling effect.If the canceling effect is not as desired, then the angular spacingcould be adjusted until the desired canceling effect is obtained. Inthis manner, an end mill or cutter could be designed that does not justvary the vibrations from cutting tooth to cutting tooth to avoidresonance, but rather utilizes the vibrations caused by the spacing ofone or more pairs of teeth to at least partially cancel out, and thussubstantially reduce or eliminate, the vibrations caused by the spacingof one or more other pairs of teeth. According to at least oneembodiment, the optimum or desired spacing which most effectivelycancels out vibrations could possibly be determined by theoreticalcalculations, measurement of the frequencies, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will now be described further with reference to theaccompanying drawings, which represent exemplary embodiments. Structuraldetails are shown only as far as necessary for a fundamentalunderstanding thereof. The described examples, together with thedrawings, will make apparent to those skilled in the art how furtherforms of the embodiments may be realized.

In the drawings:

FIG. 1 is an elevational view of an end mill according to at least oneembodiment;

FIG. 2 is an end view of a two-tooth end mill according to at least oneembodiment;

FIG. 3 is an end view of a five-tooth end mill according to at least oneembodiment;

FIG. 4 is an elevational view of an end mill according to at least oneembodiment, showing flute variation;

FIG. 4 a is a diagram of 3-flute end mill with a constant flute helixangle in each tooth and a constant flute helix angle from tooth totooth;

FIG. 4 b is a diagram of 3-flute end mill with a variable flute helixangle from low to high in each tooth and the same variability of flutehelix angle from tooth to tooth;

FIG. 4 c is a diagram of 3-flute end mill with a variable flute helixangle from high to low in each tooth and the same variability of flutehelix angle from tooth to tooth;

FIG. 5 is an end view of a six-tooth end mill according to at least oneembodiment; and

FIG. 6 is an end view of an eight-tooth end mill according to at leastone embodiment having two separate teeth off-set from theequally-divided location and two groups of equally-spaced teeth.

DETAILED DESCRIPTION OF THE DRAWINGS

There is seen in FIG. 1 a chatter-resistant end mill 10, comprising ashank portion 12 for gripping by a machine tool. Cutting portions 14, 16are seen both on the side and the end face. The cutting portion 14 isdivided into four teeth 18 by four flutes 20 disposed between the teeth18.

FIG. 2 shows a two-tooth end mill 22, and there is seen the end cuttingedge 24 of each tooth 18 at the cutting portion 16. A first angle B anda second angle C separate the two cutting edges 24 a of a first tooth 18a from the cutting edge 24 b of the second tooth. The difference betweenthe angles A and B is about 30E in the diagram but can be as high as 60Efor end mills if desired. It should be noted that A+B=360E.

With reference to the rest of the figures, similar reference numeralshave been used to identify similar parts.

FIG. 3 illustrates a five tooth end mill 26 wherein the differencebetween the first and the second angles B, C is in the range of 0.2-30degrees. The smaller differential is suitable for cutters having 5 teeth(or more) as seen in the figure. There are two pairs B C of cutting edgeirregular spacing and a single span A which is the angle resulting fromequal spacing, i.e. 72E in the example seen. The same flute profile 28is used for all teeth for simplicity of manufacture.

Turning now to FIG. 4, there is depicted an end mill 30 showingdifferent flutes 32, 34 disposed between cutting edges 36 of adjacentteeth 38. Adjacent teeth 38 are spaced apart at an angle B exceeding theangle A which would result from equal angular spacing, as seen in FIG.3.

The flute 32 relating to angle B is wider and deeper than the flute 34relating to angle A, so as to improve coolant feed and facilitate chipclearance and removal when teeth work with higher feed per teethcompared to equal tooth space dividing (by angle A).

FIG. 4 a is a diagram of a 3-flute end mill with a constant flute helixangle in each tooth and a constant flute helix angle from tooth totooth.

FIG. 4 b is a diagram of a 3-flute end mill with a variable flute helixangle from low to high in each tooth and the same variability of flutehelix angle from tooth to tooth.

FIG. 4 c is a diagram of a 3-flute end mill with a variable flute helixangle from high to low in each tooth and the same variability of flutehelix angle from tooth to tooth.

FIG. 5 shows a six-tooth end mill 40 wherein four of the cutting edgespans A are equally spaced (A=60E) while the remaining two spans B and Care irregular and in combination cover the remaining 120E.

FIG. 6 illustrates an eight-tooth end mill 42. Two groups of regularspans A alternate with two groups of irregular spaced teeth B and C.

Other cutting tools and components thereof are disclosed in thefollowing U.S. Patents and published U.S. Patent Applications: U.S. Pat.No. 6,991,409 to Noland; U.S. Pat. No. 4,497,600 to Kishimoto; U.S. Pat.No. 4,963,059 to Hiyama; US 2005/0105973 to MacArthur; US 2005/0084341to Long, II et al.; and US 2005/0117982 to Dov et al. Another cuttingtool is shown in a 2003 Kennametal Inc. brochure no. HANO3040B. Thepreceding publications, as well as all other publications mentionedherein, are hereby incorporated by reference as if set forth in theirentirety herein.

The scope of the described embodiments is intended to include allembodiments coming within the meaning of the following claims. Theforegoing examples illustrate useful forms of an embodiment orembodiments, but are not to be considered as limiting the scope thereof,as those skilled in the art will be aware that additional variants andmodifications can readily be formulated without departing from themeaning of the following claims.

1-11. (canceled)
 12. A method of making chatter-resistant end millscomprising the steps of: (a) forming an end mill having unequal angularspacing between adjacent teeth, wherein vibrations produced by theangular spacing between at least one pair of adjacent teeth isconfigured to cancel out at least a portion of the vibration produced bythe angular spacing between at least one other pair of adjacent teeth;(b) cutting a test work piece with the end mill and measuring vibrationsand resonance caused by the angular spacing between adjacent teeth; (c)upon detecting undesired levels of vibration and resonance, adjustingthe angular spacing between adjacent teeth to reduce vibration andresonance and forming another end mill having the adjusted angularspacing; (d) cutting a test work piece with the adjusted end mill andmeasuring vibrations and resonance caused by the adjusted angularspacing between adjacent teeth; (e) repeating steps (c) and (d) until anend mill is formed in which vibration produced by the angular spacingbetween at least one pair of adjacent teeth cancels out at least aportion of the vibration produced by the angular spacing between atleast one other pair of adjacent teeth; and (f) making at least oneproduction end mill conforming to the end mill produced according tostep (e).
 13. The method as claimed in claim 12, wherein the differencebetween said first and said second angles is in the range of 0.2-60degrees.
 14. The method as claimed in claim 12, wherein the differencebetween said first and said second angles is in the range of 0.2-30degrees.
 15. The method as claimed in claim 12, wherein the width anddepth of all flutes in said cutting portion is equal.
 16. The method asclaimed in claim 12, wherein a flute is disposed between two adjacentteeth, said adjacent teeth being spaced apart at an angle exceeding theangle which would result from equal angular spacing, said flute beingwider and deeper than a second flute appropriate to an equally-spacedpair of adjacent teeth.
 17. The method as claimed in claim 12, wherein aflute is disposed between two adjacent teeth, said adjacent teeth beingspaced apart at an angle less the angle which would result from equalangular spacing, said flute being narrower and shallower than a secondflute appropriate to an equally-spaced pair of adjacent teeth.
 18. Themethod as claimed in claim 12, wherein the tool has a constant flutehelix angle in each tooth and a constant flute helix angle from tooth totooth.
 19. The method as claimed in claim 12, wherein the tool has avariable flute helix angle from low to high in each tooth and the samevariability of flute helix angle from tooth to tooth.
 20. The method asclaimed in claim 12, wherein the tool has a variable flute helix anglefrom high to low in each tooth and the same variability of flute helixangle from tooth to tooth.
 21. The method as claimed in claim 12,wherein at least one group of said cutting edges is displaced from theequally-spaced position and at least one further group has cutting edgespositioned in an equally-spaced configuration.
 22. A method of makingchatter-resistant end mills, said method comprising the steps of: (a)forming an end mill having unequal angular spacing between adjacentteeth, wherein vibration produced by the angular spacing between atleast one pair of adjacent teeth is configured to cancel out at least aportion of the vibration produced by the angular spacing between atleast one other pair of adjacent teeth; (b) cutting a test work piecewith the end mill and measuring vibrations and resonance caused by theangular spacing between adjacent teeth; (c) upon detecting undesiredlevels of vibration and resonance, adjusting the angular spacing betweenadjacent teeth to reduce vibration and resonance and forming another endmill having the adjusted angular spacing; (d) cutting a test work piecewith the adjusted end mill and measuring vibrations and resonance causedby the adjusted angular spacing between adjacent teeth; (e) repeatingsteps (c) and (d) until an end mill is formed in which vibrationproduced by the angular spacing between at least one pair of adjacentteeth cancels out at least a portion of the vibration produced by theangular spacing between at least one other pair of adjacent teeth; and(f) making at least one production end mill conforming to the end millproduced according to step (e).
 23. The method as claimed in claim 22,wherein said method further comprises forming an end mill in which thedifference between the angular spacing of at least two pairs of adjacentteeth is in the range of 0.2-60 degrees.
 24. The method as claimed inclaim 22, wherein said method further comprises forming an end mill inwhich the difference between the angular spacing of at least two pairsof adjacent teeth is in the range of 0.2-30 degrees.
 25. The method asclaimed in claim 22, wherein said method further comprises forming anend mill in which the width and depth of all flutes in a cutting portionof the end mill is equal.
 26. The method as claimed in claim 22, whereinsaid method further comprises forming an end mill in which a flute isdisposed between two adjacent teeth, said adjacent teeth being spacedapart at an angle exceeding the angle which would result from equalangular spacing, said flute being wider and deeper than a second fluteappropriate to an equally-spaced pair of adjacent teeth.
 27. The methodas claimed in claim 22, wherein said method further comprises forming anend mill in which a flute is disposed between two adjacent teeth, saidadjacent teeth being spaced apart at an angle less the angle which wouldresult from equal angular spacing, said flute being narrow and shallowthan a second flute appropriate to an equally-spaced pair of adjacentteeth.
 28. The method as claimed in claim 22, wherein said methodfurther comprises forming an end mill which has a constant flute helixangle in each tooth and a constant flute helix angle from tooth totooth.
 29. The method as claimed in claim 22, wherein said methodfurther comprises forming an end mill which has a variable flute helixangle from low to high in each tooth and the same variability of flutehelix angle from tooth to tooth.
 30. The method as claimed in claim 22,wherein said method further comprises forming an end mill which has avariable flute helix angle from high to low in each tooth and samevariability of flute helix angle from tooth to tooth.
 31. The method asclaimed in claim 22, wherein at least one group of said cutting edges isdisplaced from the equally-spaced position and at least one furthergroup has cutting edges positioned in an equally-spaced configuration.